Unpowered Breakout Locking Mechanism for Flight Actuator Disengagement
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Solution Overview
Problem
Existing flight control actuation systems in aircraft require improved mechanisms for disengaging from undesired drive forces, as current systems like electromagnetic clutches and manual disengagement are inadequate.
Innovation Solution
An actuator transfer assembly with a disconnect mechanism that includes a transfer member movable between engaged and disengaged positions based on predetermined threshold forces, utilizing a magnetic and bias system to automatically disengage when exceeded, and adjustable mechanisms to set the disengagement force levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromagnetic clutches or manual disengagement systems are used, then the actuator can be disengaged from undesired drive forces, but the system complexity and energy consumption increase
Solution Approach 1:
The patent replaces electromagnetic clutches with a purely mechanical breakout mechanism. The transfer member is biased by a spring element and disengages automatically when the breakout force exceeds the bias force, eliminating the need for electromagnetic components and their associated control systems. This mechanical substitution reduces system complexity while maintaining the disengagement capability.
Solution Approach 2:
The disengagement mechanism is self-actuating and requires no external power or control. When an undesired drive force exceeds the predetermined threshold, the transfer member automatically disengages from the drive shaft due to the force overcoming the bias element's resistance. The system serves itself by using the excessive force directly to trigger the disengagement, eliminating the need for sensors, controllers, or power consumption.
2Reliability
If electromagnetic clutches or manual disengagement systems are used, then the actuator can be disengaged from undesired drive forces, but the energy consumption increases
Solution Approach 1:
The disengagement mechanism is self-actuating and requires no external power or control. When an undesired drive force exceeds the predetermined threshold, the transfer member automatically disengages from the drive shaft due to the force overcoming the bias element's resistance. The system serves itself by using the excessive force directly to trigger the disengagement, eliminating the need for sensors, controllers, or power consumption.
Solution Approach 2:
The patent replaces electromagnetic clutches with a purely mechanical breakout mechanism. The transfer member is biased by a spring element and disengages automatically when the breakout force exceeds the bias force, eliminating the need for electromagnetic components and their associated control systems. This mechanical substitution reduces system complexity while maintaining the disengagement capability.
3Ease of manufacture
If a fixed disengagement force mechanism is used, then the structure is simple, but the adaptability to different force thresholds is limited
Solution Approach 1:
The patent makes the disengagement force threshold adjustable by providing multiple bias elements with different stiffness characteristics or by allowing the selection of different spring elements. This enables the system to adapt to different force thresholds while maintaining the simple mechanical structure. The dynamic adjustability is achieved through component selection rather than complex control mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Provides reliable and adjustable disengagement of flight control actuation systems from undesired forces, preventing further force transmission and allowing for automatic latching until reset, enhancing safety and control in aircraft systems.
Implementation Method 1
the magnet (44) and the pole piece (53) may be configured such that a magnetic attractive force of the magnet (44) on the pole piece (53) exceeds an opposing bias force of the bias element (34) when the transfer member (50) is in the second position
Implementation Method 2
a bias element (34) biasing the transfer member (50) towards the first position with the pushrod (19)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An actuator transfer assembly comprising an actuator (18), a driven object (16, 116), a pushrod (19) or shaft (119), a disconnect housing (24, 124), a transfer member (50) movable relative to the housing from a first position in mechanical engagement with the pushrod or shaft such that the housing translates or rotates with the pushrod or shaft and a second position in mechanical disengagement from the pushrod or shaft such that the housing does not translate or rotate with the pushrod or shaft, a bias element (34) biasing the transfer member towards the first position, and a retainer (44, 53) configured to automatically retain the transfer member in the second position when the transfer member moves from the first position, wherein the transfer member is configured to move from the first position to the second position when a force on the pushrod or a torque on the shaft exceeds a predetermined threshold breakout force or torque.